In the wave of digital and intelligent transformation, industrial software is becoming a key factor to promote the development of new quality productivity. The 2024 Government Work Report clearly takes accelerating the development of new quality productivity as a top priority, and industrial software, as the core force of technological innovation, is leading industrial change, improving production efficiency, and promoting industrial upgrading.

Emerson Industrial Software, an industry leader, is committed to providing companies with comprehensive solutions that improve operational reliability, enhance safety and environmental measures, improve energy efficiency and productivity. Next, we will show you how Emerson Industrial software solutions enable new quality productivity through a series of co-creation examples. This issue introduces Emerson Advanced control to help Yunnan Chihong Huize Smelting Branch to achieve efficient and stable operation of roaster.

CI532V02 User profile

Chihong Zinc-Germanium was established in July 2000. It is a state-owned listed company focusing on lead-zinc-germanium industry, comprehensive recovery of rare and precious metals, and integrating geological exploration, mining, mineral processing, smelting, chemical industry, deep processing, trade and scientific research. The main equipment, environmental protection and process technology are at the leading level of the industry, and the output of lead and zinc metal and lead, zinc and germanium products in the mine ranks at the forefront of the country.

Customer challenge

The temperature of baking furnace is the key to the efficient, safe and stable operation of baking furnace. The main challenges are as follows:

🔷 The temperature of baking furnace is affected by several parameters such as feed amount, air amount, oxygen amount and furnace negative pressure.The temperature of

🔷 baking furnace has a large lag;

🔷 due to the changes of raw material composition, negative pressure, etc., the temperature fluctuation range is large, which affects the stability of the subsequent process;

🔷 The frequency of manual control operation is high, the requirements for operator experience are high, and the control quality is inconsistent.

solution

CI532V02 Through field research and in-depth communication with customers, Emerson China executive team found that the baking furnace temperature control has the characteristics of variable raw material composition, multiple interference variables, and lagging response, and a single PID controller is difficult to meet the process control requirements. Aspen DMC3 advanced control software is adopted to realize automatic control of baking furnace temperature, improve control smoothness, narrow temperature fluctuation range, reduce manual operation frequency, reduce energy consumption, and improve operation efficiency.

In the scheme, the advanced control controller takes the baking furnace temperature as the control target, establishes the baking furnace temperature prediction model, synthetically coordinates the influence of multiple variables such as feed volume, blast volume, oxygen volume and furnace load. When the interference variable (such as furnace negative pressure) changes, the model prediction controller will calculate the change of the corresponding operating variable (such as the frequency of the belt conveyor) based on the predicted data, so as to control the controlled variable (such as the baking furnace temperature) in the target range, and keep the constrained variable (such as the baking furnace feed rate, air material ratio) in the desired range.

Remarkable results

The energy consumption of the device is reduced, the output is increased, and the roasting device realizes safe, environmental protection and stable production.